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KTM DC CONVERSION HARNESSINSTALLATION
SUMMARY & BENEFITS:This installation is applicable to Trail Tech HID headlight installation, as well as general DC conversions.
• The included wiring harness is a modified OEM KTM part. It includes connections for the battery, reg/rec, stator, headlight, tail light, computer and power switch.• This wiring harness is intended to be used with a Trail Tech stator and reg/rec kit only. DO NOT ATTEMPT TO USE THIS WIRING HARNESS WITH THE STOCK STATOR AND REGULATOR!BENEFITS:• PLUG AND PLAY: No cutting or splicing required. Makes a clean installation using factory KTM connectors.• The installation is completely reversible.• The wire harness can be used with the Trail Tech battery 040-BATT3.7, or the Yuasa battery YTX4L-BS (Both sold separately)
PARTS:
Continued on other side >>
REMOVE BOLT TO
UNINSTALL STOCK
REG/REC
010-ELV-43KTM DC HARNESS
Tech Support: [email protected]
Wire Harness
Included with the kit are the following: • Wire Harness • Battery Ground Strap (w/ bolt and washer) • Battery Ring Terminal Adapters • Battery Mount Box (w/ 3 screws) • Handlebar Mounted Switch • Reg/Rec Bolt (M5x10mm SHCS)
INSTRUCTIONS:STEP 1: Begin by laying out the wiring harness and familiarizing yourself with the connectors. When installed, the Head Light, Computer, and Light Switch connectors will be located in front the of the steering stem. The Stator and Reg/Rec connectors, as well as the Ground ring terminal, will be located under the gas tank. The Tail Light and Battery + connectors will be located in the air box.
STEP 2: Remove the seat, gas tank, head light or number plate, and left side air box cover from the motorcycle. Remove the stock lighting wire harness if equipped.
Head Light
Light Switch
ComputerPower
StatorReg/Rec
BatteryPositive (+)
Tail Light
GroundRing Terminal
KTM DC CONVERSION HARNESSINSTALLATION
INSTALLATION CONTINUED:
STEP 3: Install the battery in the battery box. If using the Trail Tech 040-BATT3.7, use the two included 8” zip ties as shown. If using the Yuasa YTX4l-BS, use a KTM battery strap, part number 50303018000 (sold separately)
010-ELV-43KTM DC HARNESS
Tech Support: [email protected]
Continued on next page >>
STEP 4: Screw the battery box into place on the rear fender. Use the 3 provided screws. The bottom screw hole may not line up on some older models. If so, use alternate opening as shown.
STEP 5: Begin installing the wiring harness at the Ground Ring Terminal. Remove the forward coil Bolt (on older models, use the regulator mount), and re-install with ring terminal. Rotate all connectors towards the rear of bike before tightening bolt. Zip-tie the wire harness to the lower frame rail, routing the zip tie through the available slot in the coil mount (as shown).
STEP 6: Route the positive(+) battery and tail light connectors under the frame rails, then through the wiring notch in the air-box plastic. If installing a tail light, connect it now.
Start these two screws first.
GroundRing Terminal
Zip-Tie HarnessTo Frame
Route CablesUnder Frame Rail
Route ThroughNotch in PlasticInto Air Box
KTM DC CONVERSION HARNESSINSTALLATION
INSTALLATION CONTINUED:
STEP 7: Route the head light, computer, and switch connectors to the right side of the frame, and forward along the frame to the steering stem area.
010-ELV-43KTM DC HARNESS
Tech Support: [email protected]
Continued on other side >>
STEP 8: Install the handlebar mounted switch in the location of your choice. Connect the two spades to the headlight switch connectors of the wiring harness. The computer and headlight can also be connected at this time. If using the stock push/pull switch, connect directly to the two spaes.
STEP 9 (040-BATT3.7): Install the ground wire as shown. Screw to frame rail using provided M5 bolt and lock washer. Connect the strap to the black wire of the battery. If the frame is not drilled for the ground strap, drill with a 1/8” drill bit and attach with the included self-tapping screw and washer.
STEP 9 (Yuasa YTX4L-BS): Install the ground wire as shown. Screw to frame rail using provided bolt and lock washer. Install the provided ring terminal adapters onto the battery + wire, and the ground strap. Connect the strap to the negative terminal of the battery.
DO NOT CONNECT
DO NOT CONNECT
Handle BarSwitch Wires
Head LightConnector
ComputerConnector
LEAVE THE BATTERY POSITIVE (+) WIRE DISCONNECTED UNTILL ALL ELECTRICAL WORK, INCLUDING STATOR INSTALL, IS COMPLETE.
KTM DC CONVERSION HARNESSINSTALLATION
INSTALLATION CONTINUED:STEP 10: Zip-Tie the harness to the frame as needed using the remaining ties.
010-ELV-43KTM DC HARNESS
Tech Support: [email protected]
STEP 11: Install the stator, flywheel, and regulator/rectfier according the instructions provided with the stator kit.
STEP 12: When the stator, flywheel, and reg/rec are installed, connect the positive(+) battery wire and test the system. Once the installation is verified, re-install the left air box cover, gas tank, head light or number plate, and seat.
Wiring Diagram
Finished.
